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PLC Programming with
RSLogix 5000
How to Program Allen-Bradley
ControlLogix and CompactLogix PLCs with
Rockwell Automation’s RSLogix 5000
By Neal Babcock
engineer-and-technician.com
Copyright 2009 Modern Media
Contents
Introduction ..................................................................................................................... 4
PLCs ............................................................................................................................... 5
Hardware......................................................................................................................... 6
ControlLogix Processor................................................................................................ 6
I/O Modules.................................................................................................................. 6
Software .......................................................................................................................... 7
Getting The RSLogix 5000 Software............................................................................ 7
Ladder Logic ................................................................................................................... 7
The Dialect of PLCs ........................................................................................................ 8
Equivalent Logic ............................................................................................................ 12
Project Scope................................................................................................................ 14
Summarizing the Scope ................................................................................................ 20
Which PLC? .................................................................................................................. 21
Lay Out The I/O............................................................................................................. 21
Assigning I/O Addresses ............................................................................................... 23
Running RSLogix .......................................................................................................... 24
Tags ........................................................................................................................... 35
Adding Descriptors To Your I/O ................................................................................. 37
Writing the Program ...................................................................................................... 42
Ladder View ............................................................................................................... 42
Setting Up An Overall Control Rung .......................................................................... 42
Starting a Batch Cycle ............................................................................................... 57
Batching Steps........................................................................................................... 67
Step 1 – Adding City Water........................................................................................ 67
The Tag Database ..................................................................................................... 70
Analog Inputs ............................................................................................................. 78
Setting up the Analog Input Card to Calculate Tank Weight ...................................... 79
Setting up the Analog Input Card to Calculate Tank Level........................................ 81
Back to Batching – Step 1.......................................................................................... 83
Step 2 – Adding Chemical KM ................................................................................... 89
Step 3 – Adding Chemical KM ................................................................................... 92
Step 4 – Blending....................................................................................................... 93
Step 5 – Pump to Filling Lines ................................................................................... 99
Faults .......................................................................................................................... 101
Valve Position Faults ............................................................................................... 101
Console Status Indicators – Pilot Lights ...................................................................... 108
Adding Rung Comments ............................................................................................. 115
Connecting To The PLC And Going Online................................................................. 119
RSLogix Emulate 5000................................................................................................ 122
RSLinx ..................................................................................................................... 122
Emulator................................................................................................................... 124
Editing in Run Mode .................................................................................................... 148
2
PLC Programming with RSLogix 5000
Copyright  2009 Modern Media
Run Mode on the Plant Floor ...................................................................................... 153
Add-On Instructions & Function Block Diagram Programming.................................... 154
Creating a Function Block Diagram ......................................................................... 156
A Final Note About Our Program ................................................................................ 161
How Do I . . . ? ............................................................................................................ 162
Tips, Shortcuts and Warnings ..................................................................................... 164
Conclusion .................................................................................................................. 167
3
Introduction
The purpose of this book is to teach you how to set up, program and use an AllenBradley ControlLogix or CompactLogix. It will also familiarize you with the parts required
for a common application.
It will tell you how to use RSLogix 5000 and how to write a ladder logic program.
Since I feel the best way to learn any programming language is by using a real-world
example, there is a sample project included in this book. This sample project, which
involves a chemical batching process, also contains a Project Scope. The Project
Scope, or Functional Specification, or whatever your company might call it, defines in
detail how the system is to operate when the project is finished.
You will learn, step by step, how to take a Project Scope and turn it into a working PLC
program.
The book will show you how to go online with your PLC to monitor your program to
verify your ladder logic and make sure it is functioning properly.
It will show you how to make changes to your program while you are online.
It will show you the keystrokes and mouse movements that you need to know to use
RSLogix 5000.
Finally, it provides a number of tips and a Frequently Ask Questions section that will
save you hours of frustration.
This book assumes you have a little background with PLCs – perhaps you have worked
with other PLCs from other manufacturers or you have helped to install and wire PLCs.
Perhaps you are a Mechanical, Chemical or Process Engineer and you need to learn
how to use RSLogix 5000.
If you need a more thorough understanding of basic PLC concepts, you might want to
try the Beginner’s Guide to PLC Programming How to Program a PLC (Programmable
Logic Controller). This ebook, along with the online tutorial, provides an example of how
to automate a drill press, while explaining all the basic concepts of PLC programming
that are necessary to write a solid PLC program.
The Beginner’s Guide to PLC Programming works well in conjunction with this book, in
that it concentrates on basic PLC programming methods that are common to all types of
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PLCs. In addition, it provides an example of machine operation, whereas this book uses
the example of a chemical batching process.
The Beginner’s Guide to PLC Programming is available from Modern Media for $9.95.
Visit engineer-and-technician.com if you would like to learn more about this book.
PLCs
Nearly all the industrial equipment that you find in a modern manufacturing facility
shares one thing in common - computer control. The most commonly used controller is
the PLC, or the Programmable Logic Controller, using a programming language called
Ladder Logic. The language was developed to make programming easy for people who
already understood how switches, relay contacts and coils work. Its format is similar to
the electrical style of drawing known as the “ladder diagram”.
The most popular and most widely used manufacturer of PLCs is Rockwell Automation,
who produces the Allen-Bradley ControlLogix and CompactLogix series of PLCs. The
ControlLogix and CompactLogix families of processors and I/O modules are all
programmed using Rockwell’s proprietary software known as RSLogix 5000.
When you are finished with this book, you will be able to sit down in front of any
computer running RSLogix 5000 and create a new program. You will be able to edit
existing programs. You will be able to professionally document any changes you have
made.
Rockwell Automation Technical Support
Unfortunately, we can’t anticipate all the problems you might face as you are
troubleshooting a program on the factory floor. There are just too many variables. This
is why you must establish a relationship with your local Rockwell Automation technical
support team. Get to know them before you are in the final stages of a start-up and you
run into a problem. They are very helpful and they can save you hours of frustration.
The Rockwell reps are not just technical support personnel; they are skilled engineers
that are responsible for running their own projects and writing and troubleshooting their
own programs. If you run into a problem, more than likely they have already seen it and
have come up with a solution.
5
Hardware
One of the nice things about Allen-Bradley’s smaller PLCs is the relative simplicity of
assembling the hardware to create a system.
First, let’s see what it takes to assemble a ControlLogix system. You only need to have
a few components: a processor, a power supply, a rack and some I/O modules.
ControlLogix Processor
At the time of this writing, there are 15 ControlLogix processors available. For our
application, the 1756-L55 processor will be fine.
For your future projects, you will have to consider a number of factors before you make
the choice of your processor. Utilize your Rockwell representative and Rockwell’s
website (www.ab.com) to help you in your choice.
All the processors use RSLogix 5000, so any program you write for one processor could
be adapted to run any other 1756 processor.
I/O Modules
For our system, we need discrete inputs, discrete outputs and analog inputs. These
modules will work fine for our application:
1756-IA16 Digital AC Input Module (16 discrete inputs)
1756-OA16 Digital AC Outputs (16 discrete outputs)
1756-IF8 Analog Modules (8 single-ended analog inputs)
6
Software
All ControlLogix and CompactLogix processors use RSLogix 5000 software to program
the PLCs. Admittedly, the software is a bit pricey, but in my opinion, it is worth it.
Getting The RSLogix 5000 Software
If you don’t have access to a PLC, it would be well worth the effort to download the
demo version of RSLogix 5000. The demo runs for 90 days, and has some limitations,
but you will be gaining experience with the real thing. Currently, the software is here:
http://www.rockwellautomation.com/rockwellsoftware/design/rslogix5000/demo.html.
There are 7 sections to download, totaling slightly over 480MB. Yes, it’s a big job to
download and install it, but it is essential.
Ladder Logic
Before we open RSLogix 5000 and start programming, there are a few things you need
to know about PLCs in general. I have summarized the basic terms and techniques
required to work with ladder logic. It isn’t a comprehensive summary, but if you are just
starting out, the information presented here will be very helpful.
Every PLC programmer, no matter what skill level, must know the principles described
in this section and the Equivalent Logic section. There is simply no way around it.
To effectively write a program, or even edit one, the programmer must know how to
visualize the effects of the changes he will make.
In other words, you have to be able to look at the logic “on paper” and imagine how the
logic will work when it is entered into the PLC.
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The Dialect of PLCs
Lets' define some terms and symbols:
INSTRUCTION – RSLogix’s Relay Ladder Logic command language is comprised of
“instructions”. An XIC (it looks like a normally open contact --] [-- ) is an instruction. A
timer is an instruction. A few of the most common instructions are described below.
BIT - an address within the PLC. It can be an input, output or internal coil, among
others.
RUNG - A section of the PLC ladder program that terminates in an output function of
some type. Just like in an electrical ladder diagram, a rung has some type of output that
is turned on or turned off by the preceding entities in the rung. The first rung in a ladder
program is always 0.
HARDWIRED INPUT - a physical connection to the PLC from an input device (switch or
sensor, etc.).
RSLogix 5000 defines the address of the input, based on the input cards that you
configure.
We’ll see how this works later on, but here is an example of a hardwired input:
Local:4:I.Data.3
Here is what each part of the address means:
Local:4:I.Data.3
“Local” means that the module is connected to a controller across a backplane or with a
parallel link, keeping the module within a few inches of the controller.
Local:4:I.Data.3
“4” means that the module is module 4 (located in the 5th slot in the rack).
Local:4:I.Data.3
“I” means the bit is an input
Local:4:I.Data.3
“Data” indicates the type of data (this is the default for I/O)
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Local:4:I.Data.3
“3” indicates that the bit is 4th input on the card (the bits start with 0).
By the way, don’t get the capital “I’s” confused with ones.
So, in evaluating our example, we would describe the bit as “Module 4, bit 3”.
Here is where some confusion comes in. Because the Rockwell numbering system
starts with 0, and the processor resides in Slot 0, our example bit is actually in slot 5.
Our bit 3 is actually the 4th bit. We could also describe the bit as “Slot 5, position 4”.
You will have to learn to transpose these ways of describing a bit back and forth in your
head. If you are troubleshooting a problem, and you want someone to look for a signal
on our example bit, you might have to tell him to look at the 4th position on the 5th slot.
That will lead him to the physical point on the PLC.
However, you need to keep in mind that the corresponding bit in your program will be
labeled Local:4:I.Data.3.
It can be confusing, but you will get used to it.
HARDWIRED OUTPUT - a physical connection from the PLC to an output device (relay
or pilot light, etc.)
Outputs are addressed the same way.
Local:5:O.Data.4
“Local” means that the module is connected to a controller across a backplane or with a
parallel link, keeping the module within a few inches of the controller.
Local:5:O.Data.4
“5” means that the module is module 5 (located in the 6th slot in the rack).
Local:5:O.Data.4
“O” means the bit is an output
Local:5:O.Data.4
“Data” indicates the type of data (this is the default for I/O)
Local:5:O.Data.4
“4” indicates that the bit is 5th output on the card (the bits start with 0).
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INTERNAL COIL
This is a programmable bit used to simulate a relay within the PLC. The internal coil has
no connection to the outside world. It does not connect to an output card. Internal coils
are used to store information. The “contacts” of this “relay” can then be used multiple
times in other parts of the program.
RSLogix 5000 has greatly simplified the process of describing an internal coil. We can
simply give it a name, known as a tag.
For example, if you have an internal coil that is the result of, say, three hardwired safety
gate limit switches, we could label the coil “SafetyGatesClosed”.
Note the lack of spaces in the tag name. RSLogix 5000 does not allow spaces, or other
special characters, in the tag name.
Some people use underscores, so the tag might be “Safety_Gates_Closed”. Either way
is fine; it just depends on what your company or your client prefers.
TIMER
A timer is a programmable instruction that lets you turn on or turn off bits after a preset
time.
The two primary types of timers are TON for “timer on delay” and TOF for “timer off
delay”.
Timers in RSLogix 5000 use tag names for identification.
COUNTER
A counter is a programmable instruction that lets you turn on or turn off bits after a
preset count has been reached.
There are different types of counters available in the RSLogix, but the CTU (counter up)
instruction covers everything we will talk about here.
Counters in RSLogix 5000 use tag names for identification.
--] [-- Normally Open Contact
When used with a hardwired input, this instruction is off until there is a voltage applied
to the input. The bit address then goes high, or on, and the instruction becomes “true.” It
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works the same way when it has the same address as an internal coil, except that the
coil must be turned on by logic in the program.
Allen-Bradley calls these normally open contacts “XIC”, or “eXamine If Closed”
instruction.
An XIC instruction can reference a hardwired input, a hardwired output, an internal coil
or a timer done bit, among others.
--]/[-- Normally Closed Contact
This is an inverted normally open contact.
When used with a hardwired input, this instruction is "true" until there is a voltage
applied to the input. It then goes low, or off, and becomes “false.”
It also can be used with an internal coil, becoming true when the coil is off and
becoming false when the coil is on.
Allen-Bradley calls these normally closed contacts “XIO”, or “eXamine If Open”
instructions.
-( )- Output Coil
When used with a hardwired output, this function is off until the logic in the program
allows it to turn on. It then becomes “true”, and will energize the device that is wired to
the respective output.
If it is used as an internal coil, it will toggle the instructions associated with it. That is, it
will close a normally open instruction and open a normally closed instruction.
Allen-Bradley calls these outputs “OTE”, or “OutpuT Energize”.
An OTE may be used with a hardwired output or an internal coil.
TRUE – A state that indicates an instruction is allowing logic to “flow” through it.
Also, if the logic in a rung turns on the output of the rung, then the rung is said to be
true.
FALSE - Without stating the obvious, this is the opposite of true.
OK, that was a lot to cover and for you to understand – don’t worry, this will start getting
easier.
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Equivalent Logic
Suppose we want to use a PLC to operate a pilot light. In its elementary form, PLC logic
is very similar to the hard-wired logic you would find in an electrical ladder diagram.
For example, if you wanted to turn on a light with a momentary pushbutton, you would
wire it like the circuit below. When you press PB1, the pilot light PL1 lights up.
H
N
|
PILOT |
|
LIGHT |
| PB1
PL1 |
|---] [---------------------------------------(L)----|
|
|
|
Now let's do the same thing in a PLC. To duplicate the hardwired circuit on a PLC, you
would wire the switch PB1 to an input (let’s use Local:4:I.Data.3) and wire the light PL1
to an output (Local:7:O.Data.0).
The I/O (hardwired inputs and outputs) is set up like this:
-
There is a “PB1” pushbutton switch wired to Local:4:I.Data.3 of the PLC.
There is a “PL1” pilot light wired to Local:7:O.Data.0 of the PLC.
In RSLogix 5000, the screen would look like this.
Now let’s examine the sequence of events. When you first turn on the PLC, the PB1
pushbutton is off, or false. Therefore, the PL1 output is off. Pressing PB1 will make
Local:4:I.Data.3 true, Local:7:O.Data.0 will come on and the light will be energized. It
will stay on only as long as you hold the button in.
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Just like electrical current has to flow through the switch to turn on the light in the
hardwired circuit, the logic has to "flow" through the normally open instruction (which is
“closed” when you press the switch) of Local:4:I.Data.3 to energize the output that turns
on PL1.
The green highlight indicates the instruction, is “on” or “true”.
One nice feature of Allen-Bradley PLCs is that you can document each bit in the
program. In the example above, “PB1” is somewhat meaningless on its own. After you
add the descriptive text “Start Motor PB1”, things make more sense.
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Project Scope
We will use a batching operation as an example. Batching, as you may know, is the
term that describes the mixing of assorted ingredients to make a finished product.
There are techniques that are common to batching, whether you are making soap or
cake mix. We are going to write a program that mixes a hypothetical window cleaner.
Someone has to define the batching procedure. Usually, this is done by a process
engineer or a chemical engineer. If the job of defining the project is done well, a
document called a Project Scope (or something similar) is generated.
It is extremely important that you clearly understand the entire process that is defined in
the scope. If you have any questions or concerns, you need to resolve those before you
begin programming. If you don’t, then the responsibility of errors and omissions, and
perhaps the blame, may be placed on you.
If you bring up questions that result in changes to the defined sequence of operations,
ask the originator to revise the Project Scope. In fact, it is not uncommon for a Project
Scope to undergo a number of revisions.
If there is a change that is not documented in the scope, you should document it by
getting an email from the originator that explains the change. If nothing else, you want
to make sure you understand what the change involves.
For our project, the project scope is as follows.
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Hyper-Glass Cleaner
Batching Project Scope
Goal
The goal of this project is to install a new automated batching system for mixing HyperGlass Cleaner.
Overview
Three ingredients (city water, ingredient QR and ingredient KM) are added in specified
amounts by weight to the Mixing Tank. After all the ingredients have been added to the
Mixing Tank, the mixture is blended by running the agitator for a given time. When the
blending time is complete, the finished product is pumped to the Filling Lines for bottling
and final packaging.
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System Components
Component
Valve AV-CW
Limit Switch LS-CW1
Limit Switch LS-CW2
Pump PUMP-QR
Valve AV-QR
Limit Switch LS-QR1
Limit Switch LS-QR2
Pump PUMP-KM
Valve AV-KM
Limit Switch LS-KM1
Limit Switch LS-KM2
Scales
Agitator MTR-MTA
Pump PUMP-MT
Valve AV-MT
Limit Switch LS-MT1
Limit Switch LS-MT2
Ultrasonic Level Sensor ULS-1
Function
Supplies city water to the Mixing Tank
Indicates when valve AV-CW is closed
Indicates when valve AV-CW is open
Pumps ingredient QR to the Mixing Tank
Supplies QR to the Mixing Tank
Indicates when valve AV-QR is closed
Indicates when valve AV-QR is open
Pumps ingredient KM to the Mixing Tank
Supplies KM to the Mixing Tank
Indicates when valve AV-KM is closed
Indicates when valve AV-KM is open
Provides the current weight of the
ingredients in the tank to the PLC
Blends the ingredients in the Mixing Tank
Pumps ingredient MT from the Mixing
Tank
Supplies the finished product to the Filling
Lines
Indicates when valve AV-MT is closed
Indicates when valve AV-MT is open
Indicates the level in the Mixing tank
16
Operator Panel Layout
17
Operator Panel Components
Component
SYSTEM READY pilot light PL1
SYSTEM FAULT pilot light PL2
START BATCH pushbutton switch PB1
STOP BATCH pushbutton switch PB2
ADDING WATER pilot light PL3
ADDING QR pilot light PL4
ADDING KM pilot light PL5
BLENDING pilot light PL6
PUMPING TO LINES pilot light PL7
E-STOP PB3
Function
Indicates the system is ready for batching
Indicates the system has a fault and is
stopped
Starts a new batch
Stops the batching process
Indicates the system adding water to the
Mixing Tank
Indicates the system adding ingredient QR
to the Mixing Tank
Indicates the system adding ingredient KM
to the Mixing Tank
Indicates the system is blending the
ingredients
Indicates the system is pumping the batch
to the Filling Lines
Immediately stops the entire system
Electrical Specifications
The Ultrasonic Level Sensor ULS-1 provides a 0-10VDC signal to the PLC.
The Scales provide a 0-10VDC signal to the PLC.
All other input signals are 120VAC.
All output signals are 120VAC.
Detailed Sequence of Operations
There are 5 steps in the Batching process:
1.
2.
3.
4.
5.
Add City Water
Add Ingredient QR
Add Ingredient KM
Mix the batch
Pump the batch to the filling lines
To begin a new batch, the operator will verify that the “SYSTEM READY” pilot light is on
and that the Mixing Tank is ready to receive ingredients.
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The operator will then press the “START BATCH” pushbutton to begin the batching
process. The “SYSTEM READY” pilot light will turn off. No further operator input is
required.
Step 1 – City Water
Automatic valve AV-CW will open. The “ADDING WATER” pilot light will illuminate.
Valve AV-CW will remain open until 1275 lbs. of City Water is in the Mixing Tank. Valve
AV-CV will close.
The state of AV-CW will be verified by limit switch LS-CW2. If LS-CW2 is not made
within 2 seconds after the valve was told to open, a fault will be generated and the
system will shut down. The pilot light “SYSTEM FAULT” PL2 will illuminate indicating
that a fault has occurred.
LS-CW1 will verify that the valve is closed within 2 seconds after the valve was told to
close. If the valve closure is not verified within 2 seconds, a fault will be generated, the
system will shut down and PL2 will illuminate.
All valves and their respective limit switches will work in the manner described above.
After the City Water has been added, valve AV-CW will close and the “ADDING
WATER” pilot light will turn off.
Step 2 – Ingredient QR
Valve AV-QR will be opened. After the valve position has been verified by LS-QR2,
PUMP-QR will pump 390 lbs. of ingredient QR into the Mixing Tank. The “ADDING QR”
pilot light will be illuminated while the pump is running.
After the ingredient QR has been added to the Mixing Tank, PUMP-QR stops and the
“ADDING QR” pilot light will turn off. Valve AV-QR will close.
Step 3 – Ingredient KM
Valve AV-KM will be opened. After the valve position has been verified by LS-KM2,
PUMP-KM will pump 173 lbs. of ingredient KM into the mixing tank. The “ADDING KM”
pilot light will be illuminated while the pump is running.
After the ingredient KM has been added to the Mixing Tank, valve AV-KM will close.
PUMP-KM will stop. The “ADDING KM” pilot light will turn off.
After LS-KM1 indicates the valve has been closed, the agitator motor MTR-MTA will
start. The “BLENDING” pilot light will illuminate.
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Step 4 – Mixing
The agitator will run for 3 minutes. The “BLENDING” pilot light will illuminate.
After the agitator is finished, The “BLENDING” pilot light will turn off.
Step 5 – Pump to filling lines
Valve AV-MT will open. After LS-MT1 indicates the valve is open, the “PUMPING TO
LINES” pilot light will illuminate.
PUMP-MT will pump the entire batch to the filling lines. When the Ultrasonic Level
Sensor ULS-1 indicates that the tank is empty, PUMP-MT will turn off, valve AV-MT will
close and the batching cycle is complete. The “PUMPING TO LINES” pilot light will turn
off and the “SYSTEM READY” pilot light will illuminate.
During every phase of the batching process, the liquid level must be monitored by the
PLC. If the level rises to greater than 95% of that Mixing tank’s capacity, the system will
generate a fault and the batching process must be halted.
The operator may press the “E-STOP” pushbutton PB3 to stop the process at any time.
END OF HYPER-GLASS CLEANER BATCHING PROJECT SCOPE
Summarizing the Scope
So, what did we get from the scope? Let’s summarize:
First, 1275 lbs. of water will be added to the Mixing Tank. Then, 390 lbs. of QR will be
added. The last ingredient is KM, of which we will add 173 lbs.
After all the ingredients are in the Mixing Tank, we have to blend it for 3 minutes.
After the batch is blended, we will pump the finished product in the tank to the filling
lines.
We have to make sure all the valves open or close in less than 2 seconds. If they do
not, then we need to shut down the process.
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We need to turn on the appropriate pilot lights to indicate what stage the batching
process is in.
We need to make sure the level in the Mixing Tank doesn’t get too high. If it does, we
must shut down everything.
We need to make sure that the respective valves for the pumps are open before we turn
on the pumps.
Which PLC?
There are certainly a number of factors that will determine which PLC you need. Without
getting into all of those, let’s just say that the 1756-L55 processor has plenty of
processing power for this project and the cost is reasonable, so we will use one.
Before you can determine what modules, rack or power supply you need to buy, you will
have to know what your I/O requirements are. This involves the very critical step of
laying out your I/O.
A bit of advice here: Don’t skimp on this step. Make sure the I/O is right before you
begin programming. A mistake or omission here will cost you ten-fold further down the
road.
Lay Out The I/O
Now we need to layout the I/O. This will tell us the addresses for the I/O points, what
PLC modules we need and how the PLC modules need to be wired.
There are three types of signals in the batching system: 120VAC digital inputs (limit
switches and pushbutton switches) 120VAC digital outputs1 (valves, motors and pilot
lights) and analog 0-10VDC inputs.
List all of the components in the system that are connected to the PLC. Categorize each
component according its type (digital input, digital output or analog 0-10VDC). It is best
1
Technically, the valves themselves are not 120VAC devices, but in this case, the solenoids that
subsequently drive the valves are. Likewise, the motors that run the pumps and the agitators may not be
120VAC, but the control circuitry that operates the motors is 120VAC.
21
to do this in an Excel spreadsheet. I have provided one for this project – it is called
IO_List.xls and is included in the files you downloaded.
Try to keep associated devices together. For example, the “ADDING WATER” pilot light
should be near Valve AV-CW. This will make the electrical prints easier to read and also
help to keep the PLC program organized.
Notice the “Descriptor” column. This is a statement providing a shorthand description of
the device when the associated input is on, or true. We will use these descriptors in the
actual PLC program.
I can’t stress how important it is to get the verbiage right in a descriptor. For example,
let’s look at LS-CW1. This particular limit switch is normally open, but held closed when
the valve is closed.
When the limit switch is closed, the input to the PLC will be on.
If we used the descriptor
Limit Switch
LS-CW1
that wouldn’t tell us too much without referring to the prints. Plus, it is a little redundant,
as we know it is a limit switch based on the “LS” prefix in the device name.
If, however, we use the descriptor
City Water
Valve AV-CW
Closed
LS-CW1
then that tells us immediately, without referring to the prints, that the City Water valve is
closed as indicated by the limit switch LS-CW1.
After you go online with a PLC, if an input is energized (when used with a normally open
instruction), the symbol for the bit is highlighted. You can quickly realize the descriptor
statement is currently true.
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Now we must determine what input and
output modules we need.
This is a good time to call
your local Allen-Bradley
representative and have him assist
you in selecting the parts you
need. He can work directly from
your I/O listing and probably save
you a bunch of time.
The Project Scope said that the Scales and
the Ultrasonic Level Sensor provide 010VDC signals. We can use an Allen-Bradley
1756-IF8 Analog Module.
For the inputs, we can use the 1756-IA16
Digital AC Input Module. Since 11 inputs are
needed for the system, this card will provide 5 spares.
For the outputs, we will use a 1756-OA16 Digital AC Outputs Module.
We still need a rack to hold our processor, the I/O cards and a power supply. We are
not going concern ourselves here with the rack or the power supply, as this doesn’t
have much effect on our programming. Suffice to say, try to select components that will
provide the space and flexibility for future expansion.
Assigning I/O Addresses
Here is the final layout for the cards in the rack:
Slot 0 – 1756-L55 processor
Slot 1 – 1756-IF8 Analog Modules (8 single-ended analog inputs)
Slot 2 – 1756-IA16 Digital AC Input Module (16 discrete inputs)
Slot 3 – 1756-OA16 Digital AC Outputs (16 discrete outputs)
Please refer to the I/O List spreadsheet and you will see how the I/O has been
assigned.
A final note about the I/O list – take the time to do it right and keep it updated as the
project progresses.
23
Running RSLogix
To run RSLogix, click:
Start > All Programs > Rockwell Software > RSLogix 5000 Enterprise Series > RSLogix 5000
A quick side note about conventions used in this book:
We are going to use the format shown above to indicate what menu items you should
click on as you navigate the menus and sub-menus.
For example, the line above means:
Click on “Start”.
Click on “All Programs”.
Click on “Rockwell Software”.
Click on “RSLogix 5000 Enterprise Series”.
Click on “RSLogix 5000”.
Your path to start RSLogix, depending on the version you have installed, may be slightly
different.
24
You will see this on your monitor.
By default, RSLogix 5000 displays a “Start Page” every time the program is
started. Most people don’t use this and choose to turn it off.
Select Tools > Options and uncheck “Show Start Page on Start Up”.
25
To open a new programming, choose
File > New
In the Type: dropdown, select “1756-L55”.
In the Name field, type in “BATCHING”.
In the Chassis Type: dropdown, select the seven slot “1756-A7” chassis.
26
Click “OK” and this screen will appear.
On the left, you see an explorer-type menu. This is called the Controller Organizer. All
of these folders and files allow you to configure or view properties of the PLC or data
files within the PLC.
Tip: You can toggle the
Controller Organizer by pressing
ALT-0
27
The first thing we need to do is configure the I/O. Scroll down in the Controller and rightclick on “I/O Configuration”. Choose “New Module”.
28
Expand the “Analog” section.
Select “1756-IF8” and click “OK”.
29
Click “OK” on the next dialog box and the “Module Properties” window appears.
This window allows you to configure many aspects of the analog card, including:
-
scaling (per channel)
input range (voltage or current, per channel)
alarm configuration (per channel)
calibration gain and offset (per channel)
We will adjust these later; for the time being click “OK” to accept the default values.
Let’s add the discrete input card. Right-click on “I/O Configuration” and select “New
Module”.
Make sure that the module is assigned to Slot 1.
30
Expand the “Digital” section.
Choose “1756-IA16”.
31
A dialog box appears asking you to select the major revision. Select the default. Make
sure Slot 2 is selected and click “OK”.
32
Now we can add the discrete output card to complete our I/O configuration.
Add a 1756-OA16.
33
The Controller Organizer should look like this.
I have intentionally glossed over many of the configuration options for these cards, as I
don’t want to get bogged down in these right now. In most cases, the default
configuration for the cards will work just fine.
Later in the book, however, we will come back to the analog card to perform the
necessary setup.
34
Tags
Rockwell introduced the concept of tags with RSLogix 5000. All of the addresses in the
processor are tag based.
Scroll to the top of the Controller Organizer window and expand “Controller
BATCHING”. Click on “Controller Tags” and this screen appears.
Notice that all of the I/O cards we added are now listed in the Controller Tags section.
Local:1 is the analog input card.
Local:2 is the discrete input card.
Local:3 is the discrete output card.
35
There are different sections of tags for each card.
The “C” suffix (Local:1:C) stands for “configuration”.
The “I” (Local:1:I) stands for “input”.
The “O” (Local:3:O) stands for “output”.
Each card has its own configuration section. These sections cover the parameters that
we saw when we first added the cards.
As you might expect, the analog input card and the discrete input card have an “I”
section. The discrete output has an “O” section.
Why, though, does the discrete output have an “I” section?
Expanding Local:3:I show us that this card returns information regarding faults, data,
timestamps and fuse status.
This information can be used in the program to help troubleshoot a problem.
36
Adding Descriptors To Your I/O
A descriptor is the text that is associated with a tag. We could add a descriptor to every
tag, but that may not be cost effective. We do, however, want to add descriptors to our
I/O points.
In the controller tag window, expand “Local:1:I. Scroll down to the tag named
Local:1:I.Ch0Data. This tag holds the actual value of the signal on the first channel
(channel 0) of the analog input card.
Keep this in mind as you troubleshoot a ControlLogix processor. This is one place you
can look to see if you are getting a signal at the input of the card.
Let’s hide the Controller Organizer (ALT-0) for a moment and maximize the Controller
Tags window. The screen looks like this.
37
Open your I/O List spreadsheet and find the description for Local:0:I.Ch0Data. It is
“Liquid Weight in Mixing Tank Scales SC-1”. Copy the text (CTRL-C)
Click on the description column for Local:0:I.Ch0Data and paste the description into the
box.
Repeat the process for the remaining analog inputs.
38
Let’s do the same with the descriptors for the first discrete input card. Expand “Local:2I”.
Expand Local:2:I.Data.
These are the tags that define the actual inputs on the card. Like with the analog card,
this is where you look to see if you have a signal on an input.
39
Copy the descriptions from the spreadsheet for this card.
I have hidden the Force Mask column and stretched the Description column to see the
full description.
You can switch columns on or off in the Controller Tags window by
selecting View > Toggle Column
40
Copy the descriptions from the spreadsheet for the output card.
This completes the descriptions for the I/O.
It is a good idea to save
your work frequently. This is done
in RSLogix like it is in any other
Windows program (CTRL-S, or File
> Save or
).
41
Writing the Program
Ladder View
Open the Controller Organizer, expand the “Tasks” folder, and expand the “Main
Program” folder.
Click on “Main Routine” and you should see this.
Setting Up An Overall Control Rung
Typically, a program will start with some kind of overall or master control rung. This rung
will define a bit that must be on for the entire system to operate, and we include bits that
we know must be true for the whole system to run.
42
In this project, we certainly want the E-Stop to be part of this logic. Our E-Stop (or,
emergency stop) pushbutton switch is wired in such a way that the input must be on for
the system to operate.
You can add a rung by right-clicking on the rung number and
selecting “Add Rung” from the dropdown menu.
You can also press CTRL-R.
We want to use the E-Stop input in this rung. Find the XIC (examine if closed)
button in the User menu.
tool
You can insert the instruction in a couple of ways. Simply clicking on the XIC icon will
add it to the rung.
You can also click, hold and drag the tool to the spot in the rung where you want it
inserted.
43
Click and drag it toward the new rung you just created. You will see that as you get near
the rung, a green dot will appear. Green dots represent possible landing points for your
instruction.
44
Release the mouse button and your screen should look like this.
45
Press the enter key on your keyboard. A dropdown menu appears above the instruction.
46
Open the dropdown and your screen now looks like this.
Notice that all the tag groups from our I/O are now showing.
47
From the I/O list, we see that the E-Stop switch is wired to the last position on the input
card, giving it an address of Local:2:I.Data.15. We want to find that tag in this window.
Expand the tag group Local:2:I, then expand the tag group Local:2:I.Data.
48
Click on bit 15 in the box to assign that address to the instruction.
49
Click and drag the OTE (output energize) tool button
the new rung. Place it on the marker at the right.
from the User menu down to
50
The screen looks like this.
51
Click on the blue box (the tag name field) above the instruction. Type the phrase
“SystemEnable” into the box and press enter.
Since this is a tag name, there can be no spaces or special characters in the name.
52
This is a new tag for this program, so we have to define it. Right-click on the blue tag
name field.
From the dropdown menu, choose “New System Enable”.
53
The “New Tag” dialog box appears.
The tag we are defining here is simply a bit, so we can accept the default values in the
dialog box. In fact, we really don’t need to add a description, as the tag name itself is
pretty self-explanatory.
Click “OK”.
54
We know from the Project Scope that the system must stop if there is a fault. We are
not sure of the details of all those faults yet, but we do know that we will summarize
those faults somewhere in the program. It will result in a bit. We will use the address tag
“SystemFault” for that bit. We also know that we want the “SystemEnable” to be on if we
do not have a fault.
Bear with me here and it will make sense. Click and drag the XIO (examine if open) tool
button
from the User menu down to the new rung. Place it just to the right of the
E-stop input. Double-click on the tag filed and type “SystemFault” in the box.
It should look like this:
Right-click on the tag name and define the tag (you may also press CTRL-W to get to
the “New Tag” dialog box). By the way, if you forget to define that tag, RSLogix 5000 will
remind you when you accept the rung edits.
Let’s see what we have. The logic of the rung works just like an electrical circuit. If the
E-Stop is cleared and there is not a System Fault, the System Enable bit will be on.
That is exactly what we want. We will work out the fault logic later.
55
We need to accept the current rung. Right-click on the rung number (0) and this
dropdown appears.
56
Choose “Accept Pending Rung Edits”.
We have completed the first rung in the program.
You may wonder why the SystemFault instruction is highlighted green. This is because
the value of the SystemFault tag is 0. Since the instruction is an XIC, or Examine If
Closed, the instruction is true. Therefore, the instruction is highlighted.
You should note that these colors are highly configurable. In fact, I have seen many
different color schemes. Just keep in mind that you may look at someone else’s laptop
and find blue, for example, has been configured to highlight a bit that is true.
Starting a Batch Cycle
The Project Scope said that the operator may start a batch by pressing the “Start Batch”
pushbutton on his console. Let’s start with that input.
57
Right-click on the last rung and choose “Add Rung”. Click and drag the XIC (examine if
closed) tool button
from the User menu to the left side of the new rung.
Click on the tag name field above the instruction and navigate through the tag groups
until you find the input Local:2:I.Data.0. This is the “Start Batch PB1” pushbutton.
Click and drag the OTE (output energize) tool button
the new rung. Place it on the marker at the right. We are creating a new tag that
indicates the system is currently batching. Label this tag “SystemBatching”. Right-click
on the tag, select “New SystemBatching” and accept the defaults.
If the operator chooses, he may stop the batch. We will make use of the “Stop Batch”
pushbutton. Click and drag the XIO (examine if open) tool button
from the User
menu down to the new rung. Navigate through the tag groups until you find the input
Local:2:I.Data.1. This is the “Stop Batch PB2” pushbutton.
We don’t want the operator to be able to start a batch if the System Enable bit is not on.
We will add that by dragging the XIC (examine if closed) tool button
side of the new rung.
to the left
RSLogix 5000 lets us quickly assign a tag to this bit by dragging the bit name from
another rung.
Click, hold and drag the tag name “SystemEnable” from the OTE in Rung 0. As you
drag the tag name box, you will see gray rectangles appear, indicating that these are
potential places to assign the tag. As the cursor gets nearer to a target, that target icon
changes to a green oval.
58
Release the mouse button when the cursor is near the first instruction in the rung.
59
Here is what we have so far:
This rung we are creating will work much like a traditional motor starter circuit that uses
a contact from the motor starter wired in parallel with the start button to hold in the coil.
In the PLC, the “contact” is an XIO with the same tag as the “coil”, which is
“SystemEnable”.
60
We need to “wire the contact” in parallel with the start button. We do this with a branch
instruction. Drag the Branch tool button
System Enable bit and the Start Batch bit.
and place it on the marker between the
61
Click on the blue section of the branch and drag it to the target to the right of the Start
Batch PB1 instruction.
As you are dragging, it looks like this.
62
Release the mouse button and the branch will appear around the Start Batch bit.
63
Click and drag the XIC (examine if closed) tool button
left side of the new branch.
from the User menu to the
We want this instruction to be tagged “SystemBatching”, just like the OTE in this rung.
There is a quick way to do that. Just click and drag the “SystemBatching” tag name from
the OTE in this rung to the new instruction.
This is called a latching rung. If the SystemEnable bit is on, the SystemBatching bit can
be latched by momentarily pressing the Start Batch pushbutton. The SystemBatching bit
will stay on and the rung will remain latched until the Stop Batch pushbutton is pressed
or the SystemEnable bit goes off.
Thinking ahead, though, we know that the system will stop the batch automatically after
it has pumped all the finished product to the filling lines. We are not sure how we will
know that yet, but we know we need a bit to unlatch the rung.
Click and drag the XIO (examine if open) tool button
the marker just in front of the SystemBatching OTE instruction. Type in the tag
“BatchComplete” and define the tag (CTRL-W).
64
Right-click on the rung number and verify the rung. It should appear like this.
Notice how the rung has become too long to be contained on one line, so RSLogix is
putting the OTE instruction below and re-routing the connecting line. It is accurate, but a
little confusing.
You can get around this by a couple of ways. You can set the “Zoom” factor under the
“View” menu to get the rung to appear on one line.
65
You can also hide the Controller Organizer by pressing “ALT-0”. That is what we will do
here. We don’t have a real need to see the Controller Organizer right now, anyway.
66
Batching Steps
As you recall from the project scope, there are a number of steps needed to create the
finished product. They are:
1. Adding City water
2. Adding chemical QR
3. Adding chemical KM
4. Blending the mixture with the agitator
5. Pumping the finished product to the filling lines
Step 1 – Adding City Water
We need to initiate Step 1. Before we do that, though, we need to add another
permissive bit. We will tag that bit “SystemReady”.
We know that if the system is enabled but not currently batching, it is ready to begin a
batch. We need insert a new rung and create a “SystemBatching” and “SystemReady”
bit.
Add a new rung and program it as shown in Rung 2.
67
You can see how Rung 2 should look in the picture below. The “SystemReady” bit will
be on when the system is enabled, but not batching.
To actually initiate the batch and hold the batch in Step 1, we are going to use the
Output Latch (OTL) instruction. This instruction works in conjunction with the Output
Unlatch (OTU) instruction. The instructions will work on the same bit address, but are
typically found on different rungs.
The batch will be started when the operator pushes the Start Batch button. We will latch
that bit and label it Step 1.
Insert a new rung at the bottom of the ladder. We need an XIC for the SystemReady bit
and an XIC for the Start Batch pushbutton at the beginning of the new rung.
Click and drag the XIC (examine if closed) tool button
from the User menu to the
left side of the new branch. Drag the “SystemBatching” tag from Rung 2 to the new
instruction.
68
To save some typing, you can copy and paste instructions. Highlight the Start Batch
instruction in Rung 1 by clicking on the XIC icon.
Press CTRL-C.
Click on the rung number for Rung 3.
Press CTRL-V. The instruction is duplicated on Rung 3.
Click and drag the OTL (output latch) tool button
from the User menu to the right
side of the new branch. Type in the tag name “BatchStep1” and define the new tag.
However, what if the button is pressed if the system is already batching and in another
step? To prevent that from happening, we will make sure that the only way the system
can enter Step 1 is if it is not in another step already.
69
Add a series of XIO instructions and tag them BatchStep2, BatchStep3, BatchStep4 and
BatchStep5. Define all the new tags Type in the appropriate descriptors. Verify the rung.
You may wonder why we chose not to use the OTL output latch instruction in Rung 1.
Many times, it is a matter of personal choice; sometimes a “traditional” latching rung is
better than using an OTL. In Rung 1, we were able to keep all the logic affecting the
SystemBatching bit on one rung. This makes it easier to read and a little more
condensed. Some people view a traditional latch as a bit safer. It’s your call, though.
The Tag Database
In looking at Rung 3, we see that some descriptions are a bit lacking. The
“SystemBatching” tag name explains what the bit does, but the “Batch Step” tag names
don’t tell us much. We need to add some descriptions.
70
You remember the actions for each Batch Step:
1. Adding City water
2. Adding chemical QR
3. Adding chemical KM
4. Blending the mixture with the agitator
5. Pumping the finished product to the filling lines.
We can right-click on the “BatchStep1” tag in the OTE and choose “Edit BatchStep1”
properties. We can then add the text “Adding City Water” to the description box, as is
shown below.
71
The result is this:
Since we have three more tags to define, let’s take a look at the tag database.
First, though, we need to know that RSLogix 5000 has different categories for tags.
Rockwell calls this attribute of a tag Data Scope.
There are controller tags, or global tags, that can be used by all the tasks and
programs in the PLC.
There are program tags, or local tags, that can be used only by an individual program.
When tags are created as we have done, this is the default.
Let’s take a look at the tags we have so far in the Tag Monitor.
Press ALT-0 so the Controller Organizer comes back into view.
72
Double-click on “Controller Tags” under Controller BATCHING. These are the tag
groups that were assigned when we added our I/O.
73
Double-click on “Program Tags” under Tasks > Main Program. Here are the tags we
created as we wrote the program.
74
Hide the controller organizer (ALT-0) and we can see the descriptions.
75
Let’s add the rest of the batch step descriptions.
Click on the “Edit Tags” tab at the bottom.
You’ll notice that some of the fields in the table are different.
76
Select the “Description” field for BatchStep2 and type in the description.
77
Click on the description field for each batch step and add the respective description.
One note, though; use care when you are editing tags in this table. Many times, there is
no undo available.
Analog Inputs
Before we continue with Step 1, we need to scale the analog cards for the Mixing Tank
Scales and the Ultrasonic Level Sensor.
There are a couple of ways to scale a value we get from an analog input in RSLogix
5000. We can scale the value within the program, or we can do the scaling right in the
card.
There are advantages and disadvantages to both methods. Scaling in the card is simple
and straightforward, but once the card is configured, the configuration cannot be
changed unless the PLC is taken offline. This is not good for processes that must run
continuously.
78
Scaling in the program is more difficult, but adjustments to the scaling algorithm can be
made while the PLC is still running.
In our case, as in many batching applications, the process does not have to run
continuously. For example, when the mixing tank is full, we could shut down the PLC
and manually run the pump that empties the tank. This “window” would give us more
than enough time to re-configure the analog card.
To configure our 1756-IF8 analog input card, we need to know what signal type we
have coming from our sensors, the range of the signals we get from our sensors and
the engineering units for each sensor.
Let’s start with the scales.
Setting up the Analog Input Card to Calculate Tank Weight
Scales are for these types of applications usually consist of a standalone unit that is
calibrated by the manufacturer of the scales. The unit usually has a display that shows
the actual weight and an output that can be fed to a PLC. Let’s assume that the output
of our unit has been calibrated for 0-10 VDC. Zero volts equals 0 pounds, and 10 volts
equals 2000 pounds.
Now we know the signal type is DC voltage, the range is 0-10 and the engineering units
are pounds.
79
Right-click on the 1756-IF8 card in the Controller Organizer and choose “Properties”.
Click on the “Configuration” tab and you will see this.
You’ll see that Channel 0, which is our Scales channel, is selected.
Click on the dropdown menu for “Input Range” and select “0V to 10V”.
Change the “Low Signal” field to 0.
Change the “High Engineering” field to 2000.
Change the “Low Engineering” field to 0.
That is all we really need to do. However, we are going to take advantage of the fact
that there is a filter available. This filter smoothes input transitions.
Set the “Digital Filter” field to 1000 ms.
80
Click “Apply” and we are done with the scales.
Setting up the Analog Input Card to Calculate Tank Level
Like the scales, the ultrasonic level sensor is calibrated to a 0 to 10VDC signal. Zero
volts indicate the tank is empty. Ten volts indicates the tank is at its “full “ mark,
hopefully a safe distance from its actual maximum capacity.
The engineering unit used for the tank level is percentage.
81
Select channel 1 on the card.
Click on the dropdown menu for “Input Range” and select “0V to 10V”.
Change the “Low Signal” field to 0.
Change the “High Engineering” field to 100.
Change the “Low Engineering” field to 0.
Again, that is all we really need to do, but we will set the “Digital Filter” field to 1000 ms.
82
Click “Apply”.
Back to Batching – Step 1
Double-click on the “MainRoutine” in the Controller Organizer, and then hide the
organizer.
Scroll down and add a new rung at the bottom of the ladder.
We will open the city water valve in this rung, so we want to make sure that it is still safe
and desirable to open the valve. That is, make sure that there are no faults, the E-Stop
button has not been pressed and the Stop Batch pushbutton has not been pressed.
Using an XIC with the SystemBatching bit will confirm all of that.
Insert an XIC. We could drag the tag “SystemBatching” from Rung 3, but let’s add it by
using the dropdown tag menu on the instruction.
Double-click on the tag name field above the instruction. At this point, you could type
the tag name and press enter to assign the tag to this instruction.
83
Let’s use the dropdown, though. Click on the arrow in the dropdown header and you
see this.
Scroll down until you find the “SystemBatching” tag. Select it and press enter.
RSLogix gives you a number of ways to assign a tag name. Use whatever is easiest for
the particular situation.
Since we only want to open this valve and add city water in Step 1, insert an XIC with
the tag “BatchStep1”.
Insert an OTE for the city water valve (Local:3:O.Data.1).
Remember that we want to put 1275 lbs. of water in the Mixing Tank. We will use the
LEQ (Less than or Equal To) instruction to accomplish that.
84
Scroll to the right in the Language Element toolbar until you see the “Compare” tab.
Click on it.
85
Click and drag the LEQ tool button to the marker just to the left of the OTE.
86
Source A in the instruction is the Tank Weight. Click on the blue tag field and scroll
through the tags until you find Local:1:I.Ch0Data (Liquid Weight in Mixing Tank Scales).
Press enter.
Source B is our setpoint, which as you recall from the Project Scope is 1275 lbs. Enter
1275 for Source B.
The LEQ instruction will remain true as long as the tank weight does not exceed 1275
lbs.
After the correct amount of city water has been added, we need to proceed to Step 2.
87
We will make use of the fact that we know the system is currently in Step 1, but the
Mixing Tank has enough water (1275 lbs) to go to the next step.
We will use the OTU (Output Unlatch) instruction to turn off the bit we latched in Rung 3.
Rung 5 works like this:
The XIC instruction “BatchStep1” is on. The Mixing Tank weight has reached the
setpoint of 1275, so the GEQ (Greater Than or Equal To) instruction is also true. As a
result, the bit “BatchStep1” is unlatched (turned off) and “BatchStep2” is latched (turned
on).
Take a moment to make sure you understand how as the weight in the tank rises past
1275, the City Water valve is turned off and the system transitions to Step 2.
88
Step 2 – Adding Chemical KM
Step 2 will be similar to Step 1, so rather than creating new rungs from scratch, we are
going to copy and paste the rungs from Step 1.
Click on the rung number for Rung 4. Hold the SHIFT key and click on the rung number
for Rung 5. A green bar surrounds both rung number blocks.
Press CTRL-C.
Press CTRL-V. You now have new rungs, 6 and 7.
We will start with rung 6.
Change “BatchStep1” to “BatchStep2” (in this instance, just double-click on the tag
name and change the “1” to “2” and press enter).
89
We will be looking for a setpoint of 1275 + 390, since there is already 1275 lbs. of water
in the Mixing Tank and we need to add 390 lbs. of QR. Change Source B in the LEQ
instruction to 1665.
Refer to your I/O list spreadsheet and note that the QR automatic valve is addressed as
Local:3:O.Data.3. Assign that to the OTE.
In Rung 7, change “BatchStep1” to “BatchStep2”.
Change Source B in the GEQ instruction to 1665.
Change the OTU (Output Unlatch) instruction from “BatchStep1” to “BatchStep2”.
Change the OTL (Output Latch) instruction from “BatchStep2” to “BatchStep3”.
It should look like this.
90
There is a major process difference between adding City Water and adding QR – the
QR chemical needs to be pumped. This means that not only do we have to open a
valve, but we also have to turn on a pump.
First, we want to make sure the valve is being instructed to open, so we will use an XIC
from pump AV-QR in the logic. Next, we will wait to turn on the pump until the valve is
verified to be open by limit switch LS-QR2. As a failsafe, we will look at limit switch LSQR1 to make sure it is not indicating the valve is closed.
Right-click on Rung 6 and choose “Add Rung”.
So that you can learn a bit more about ASCII editing, we will construct the entire rung
from the ASCII command line.
Double-click on Rung 7. The ASCII string input box appears. Type in the following
string:
XIC Local:3:O.Data.3 XIO Local:2:I.Data.4 XIC Local:2:I.Data.5 OTE Local:3:O.Data.4
91
Press enter and the instructions appear.
OK, maybe that wasn’t the best application for the ASCII editor, but at least now you
know it can be done.
Step 3 – Adding Chemical KM
Step 3 will have the same logic as Step 2, so will cut and paste to create new rungs.
Click on Rung 6, hold down the SHIFT key and click on Rung 8 to select the new rungs.
Press CTRL-C. Click on the last rung and press CTRL-V.
Change all the tag names for XIO and XIC instructions to match the new step.
We will be looking for a setpoint of 1665 + 173, since there is already 1665 lbs. of water
in the Mixing Tank and we need to add 173 lbs. of KM. Change Source B in the LEQ
instruction to 1838.
92
Change Source B in the GEQ instruction to 1838.
Change the latch and unlatch outputs to increment the system to Step 4.
It should look like this after you have made the changes and verified the rungs.
Step 4 – Blending
After all the ingredients are in the Mixing Tank, we have to run the Agitator for 3
minutes.
We will set up a timer to run for 3 minutes. When the timer is done, we will increment
the system to Step 5. That will turn off the Agitator.
Start by inserting a new rung at the bottom.
Insert an XIC instruction with the address of B3:0/2.
Insert an XIC instruction with the address B3:0/13.
93
Click the “Timer/Counter” tab on the Language Element menu. Click and drag the TON
tool button down to the right side of the new rung.
This type of timer is called a Timer On Delay. As soon as the instructions preceding it
are true, it will begin timing. The Enable bit (EN) will turn on. After it reaches its Preset
value, the Done bit (DN) will turn on.
First, we have to assign a tag name to the timer. Double-click on the “Timer” field in the
instruction. Type “AgitatorRunTime” for the tag name.
Define the new timer tag name, as you cannot assign presets until you do this.
The time base for the TON instruction is always 1 msec.
We want to time for 3 minutes, or 180 seconds, so we will enter a preset of 180000.
Double-click on the Preset field and type 180000. Press enter.
Leave the accumulated value at 0, as this will be changed as the timer begins timing.
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The completed rung looks like this.
To run the Agitator, insert a new rung at the bottom.
Click on the “User” tab of the tool button menu and drag an XIC instruction to the first
marker of the new rung. We will use the Enable bit (EN) of the timer for the tag.
95
To assign a timer’s enable bit, double-click on the tag name field for the new XIC
instruction and navigate to the EN (enable) bit of the timer.
96
Add an OTE instruction for the Mixing Tank Agitator.
The enable bit of a timer is on only when the timer is enabled. In Rung 12, for example,
if the SystemBatching bit turns off, or the Batch Step 4 bit turns off, the timer will no
longer be enabled. Consequently, its enable bit, AgitatorRunTime.EN will turn off.
We will turn off the timer by incrementing the system to the next step when the timer is
done.
97
Insert a new rung at the bottom and drag an XIC to the first marker. We will assign the
Done bit (DN) of the timer to this instruction. It is formatted just like the Enable bit,
except you use .DN as the suffix. Tag this instruction as AgitatorRunTime.DN.
We will use the same method to increment the system to Step 5 that we have used
previously. Drag an OTU instruction to the last marker in the rung. Tag the instruction
to be Step 4, which is BatchStep4.
Insert a new branch around the OTU by dragging a Branch tool button to the marker in
front of the output. Grab the right leg of the branch and move it to the marker after the
output.
Insert an OTL instruction on the bottom of the branch and tag it as BatchStep5.
Now, when the timer is done and AgitatorRunTime.DN turns on, it will unlatch Step 4
and start Step 5.
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Step 5 – Pump to Filling Lines
Since this step involves a pump, it will be similar to Step 3. Let’s save ourselves some
typing and copy all of Step 3.
Click on Rung 9. Hold down the SHIFT key and click on Rung 11.
Press CTRL-C.
Click on the last rung. Press CTRL-V.
In Rung 15, change BatchStep4 to BatchStep5.
Change the tag of the output instruction to Local:3:O.Data.13.
We want to pump until the Mixing tank is empty.
We will use the Ultrasonic Level Sensor to determine if the tank has liquid in it. We will
use a GEQ instruction to accomplish this.
Double-click on the “LEQ” text in the LEQ instruction. Type GEQ (for Greater than or
equal to) in that space. Change Source A of the instruction to Local:1:I.Ch1Data. This is
the address of the scaled level sensor.
We may be tempted to put a value of 0 into Source B, but that could be risky. First,
pumping the tank dry might be hard on the pump. Second, because of drift in the level
sensor, we might never get a reading of zero in some instances.
The Process engineers have told us that emptying the tank to 3% is desirable. Put a 3
in for the value of Source B.
Change Rung 16 to show the correct valve, limit switches and pump addresses.
Since this is the last step in the batching process, we will use Rung 17 to increment out
of Step 5 and complete the batching cycle.
Change the first XIC in Rung 17 to BatchStep5.
Copy the GEQ instruction from Rung 16. Click on the instruction, press CTRL-C and
click on the GEQ instruction in Rung 18. Press CTRL-V.
Delete the other GEQ from Rung 17 (the one that references the tank weight).
Change the remaining GEQ in Rung 17 to a LEQ.
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Change the OTU instruction’s tag from BatchStep3 to BatchStep5.
Right-click on the OTL (L) instruction in the bottom branch. Choose “Change Instruction
Type” and make it an OTE. Change the tag to BatchComplete. This is the “batch
complete” bit.
The screen should look like this.
When the system enters Step 5, the Mixing Tank will be nearly full. The GEQ instruction
will be true and open the Mixing Tank valve.
When the valve has been opened and verified by the limit switches, the pump will run.
When the level in the tank drops to 3%, the valve will close and the Mixing Tank pump
will stop.
Simultaneously, the BatchStep5 bit will be unlatched and the BatchComplete OTE
instruction will be turned on. It will trip the latch in Rung 1 and turn off the
SystemBatching bit.
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The system returns to its idle state and is ready to begin a new batch.
Faults
The program may be complete in an operational sense, but we need to add the logic to
detect faults.
Valve Position Faults
We were told in the Project Scope that the valve position must be verified by the limit
switches within 2 seconds.
We will use an individual timer for each valve to accomplish this.
Type in the logic as shown below.
101
We must accommodate the two conditions that indicate a fault. The first is that the valve
was told to open, but did not open. The second fault condition is that the valve was told
to close, but did not close.
Remember that the limit switches on the valves are electrically normally open and will
be physically held closed by the valve when it is in position.
When the valve is open, we should get a signal to the input Local:2:I.Data.3 when limit
switch LS-CW2 is activated by the valve.
When the valve is closed, we should get a signal to the input Local:2:I.Data.2 when limit
switch LS-CW1 is activated by the valve.
We use the XIO (examine if open) instruction. We want to know if we do not get a signal
from the limit switches when we should. An XIO instruction used on an input will always
be true if there is no signal on the input.
Let’s look at how it handles the first fault condition (the valve was told to open, but did
not open).
The City Water valve output is on but the limit switch LS-CW2 is electrically open. That
means the XIO instruction for LS-CW2 in Rung 18 is true. This creates an undesirable
condition and the timer will begin timing.
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The screenshot below shows what the state of the instructions would be after 1 second
of the valve being instructed to open, but LS-CW2 not yet being activated.
You can see that the City Water valve is being told to open, as Local:3:O.Data.1 is
highlighted. You can also see that LS-CW2 says that the City Water valve is not open,
as it is also highlighted. The timer has begun timing and has reached, or accumulated, 1
second.
If the timer reaches 2 seconds, the timer done bit ValveAVCWFault.DN will come on
and turn on the SystemFault bit in Rung 19.
Since we used the SystemFault bit in Rung 0, this will cause the SystemEnable bit to
turn off.
Consequently, Rungs 1 and 2 will become false and the system will stop batching.
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Let’s look at the other condition; that is, the valve was told to close, but did not close.
That is accomplished in the branch in Rung 18. If the valve output is not on but the limit
switch is not activated, then the timer will begin and generate a fault.
Sometimes it gets confusing when you are working with the XIO instruction. The logic is
inverted and you have to flip some things around in your head.
The logic we have used here to detect a valve fault is fairly standard and its use is
widespread. The nice part about this logic is that it is pretty easy to troubleshoot. You
can physically look at the valve to see if it is open or closed. Then, you can look at the
input you are receiving from the limit switch. If you are getting a fault when you should
not, then just invert the instruction for the limit switch. Change it from an XIO to an XIC,
or vice versa.
Let’s create the fault timers for the remaining valves. This is the screenshot for the QR
valve and KM valve fault logic.
104
This is the screenshot for the Mixing Tank valve fault logic.
105
Notice how the System Fault rung has grown.
106
To complete our fault logic, we need to add the Liquid High Level alarm. We can
achieve this with one GRT instruction in the System Fault rung. It is agreed that if the
liquid level reaches 95% of the tank’s capacity, it will fault.
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Console Status Indicators – Pilot Lights
I have held off putting the logic in for the Pilot Lights in an effort to keep the text as
simple as possible. Now that you understand how the system operates, we can go back
through the program and add the pilot lights.
The first is the System Ready PL1 pilot light. Find Rung 2 in the logic.
Insert a branch around the SystemReady output. Put an OTE instruction on the bottom
rung of the new branch and tag it Local:3:O.Data.0. With this logic, the light will come on
when the SystemReady bit is on.
We will add the remaining pilot lights in a similar fashion.
108
Adding water
109
Adding QR
110
Adding KM
111
Blending
112
Pumping to Lines
113
System Fault
We need to add a little logic to the System Fault pilot light. This light needs to stay on
after it detects a fault; otherwise, the system will stop, the light may go out and the
operator won’t know there was a fault.
We are using the STOP BATCH pushbutton to reset the fault light.
Add the rung as shown below.
114
Adding Rung Comments
A good rung comment explains in plain language what the rung is supposed to do.
These are very valuable. First, it is a way to double-check your own work. I have been
surprised at the number of times I have found a mistake in my logic as I was writing the
rung comments!
Second, it helps a person who is unfamiliar with the program quickly learn how the
program is supposed to work.
Finally, it adds value to your finished program. A well-documented program is worth
more money to a client (or your company) than a program that is not documented.
They can even get you out of a jam. If you have to troubleshoot a system 6 months after
you first programmed it, I can guarantee that you will not remember every reason for
every line of code you wrote. If you have written code in some other language before,
you certainly can understand the value of documenting your work.
115
Let’s use a rung from our program as an example. Right-click on the rung number 7 and
choose “Edit Rung Comment”. The rung comment box appears above the rung.
Type this in the Rung Comment field:
Run QR pump PUMP-QR after the QR valve is opened and the valve position is verified
by both valve limit switches. Turn on the "Adding QR" pilot light.
116
Notice that you don’t have to put details such as PLC tags in the rung comment – just
document the concept of the rung.
117
Click anywhere outside of the comment box and the comment appears above the rung.
118
Connecting To The PLC And Going Online
You have written your
program and now you are
ready to download, or send,
the Batching program to the
computer.
WARNING
First, backup up your original
file and put it in a safe place.
Connecting to a ControlLogix
processor is done through
Ethernet, the same way you
connect a PC across a
network.
There are dangerous voltages present on
terminals of the PLC. Follow all warnings
and instructions from the Allen-Bradley
manual for connecting power to the PLC. If
you are not familiar with hazards and the
potential dangers of these voltages STOP
RIGHT NOW. Consult a trained
professional who is able to assist you.
Typically, most ControlLogix PLCs are connected through an Ethernet switch. You
simply plug your computer into a open port on the switch.
Click on Communications > Who Active
119
A window similar to this will appear:
Navigate to the PLC to which you would like to connect. When you are successful, the
“Upload” and the “Download” buttons on the right will become available; they will no
longer be grayed out.
120
You will then be able to download your program by following the prompts.
Let me say that I have greatly oversimplified this process. To be frank, this is where
many people have problems. Sometimes connecting to a PLC is as easy as finding an
Internet site in your browser. Other times, it can be an incredibly frustrating experience,
due to no fault of your own.
Do what you can to prepare yourself by asking others about connecting to this particular
PLC, making sure your computer can connect to a similar PLC, and so on.
Anybody who has ever connected to a PLC has had problems; they will understand
your position.
There was one instance where the firmware in a particular PLC was not compatible with
the version of RSLogix I was running in my laptop. It took a call to Rockwell’s Tech
Support to sort out the problem. They were very helpful, and it wasn’t long before I was
connected
Tip: In Allen-Bradley PLC vernacular, upload means get the
program from the PLC and load it in RSLogix on your computer.
Download means send the program from RSLogix on your computer to
the PLC.
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RSLogix Emulate 5000
Rockwell offers a nifty way to simulate going online. You can test your program at your
desk, without being connected to a PLC. You can toggle virtual I/O points, change
values in the virtual processor and see the results real time, just like you would if you
were connected to the PLC.
The software that allows you to do this is called RSLogix Emulate 5000. If you don’t
have it installed on your computer, I highly recommend that you do so.
RSLinx
Before you can configure the emulator, you must install the emulator driver in RSLinx.
To configure RSLinx, click Start > All Programs > Rockwell Software > RSLinx > RSLinx Classic
Click Communications > Configure Drivers
Click the dropdown to add a new driver. Choose “Virtual Backplane”
122
Your screen should look like this.
Click “Close”.
123
Emulator
To run the emulator, click Start > All Programs > Rockwell Software > RSLogix Emulate 5000
You will see this.
Choose Slot > Create Module > Emulator RSLogix Emulate 5000 Controller
124
Follow the prompts and this should appear.
Change the Controller Type in the Batching Program
Before you can emulate a ladder logic project, you must configure the project's
controller type to use the emulator. At this point, I make a copy of my working file as a
precaution, as we need to alter the I/O Configuration to get the emulator to work.
The emulator needs to have the processor in Slot 1. You may try to run the emulator
without changing the I/O, but frankly, I have always had to re-configure the I/O to get
things to work.
Click Edit > Controller Properties. The Controller Properties window opens. Click the “Change
Controller” button and select “Emulator RSLogix Emulate 5000 Controller”. Close the
window.
125
Starting with the module in Slot 3, right-click on each module in the controller organizer
and bump the slot number up by one, until the configuration is as shown below:
126
Click Communications > Who Active
Expand the tree until your emulator is shown. Click the “Download” button to send the
file to the emulator.
The next step is to go online.
Find the mode drop-down menu in the upper left. It currently says “Offline”.
From the dropdown menu, choose “Go Online”.
127
The processor is now in Remote Program mode.
128
You see that the I/O is not responding as indicated by the green light in the status area.
Also, there are fault symbols showing in the I/O Configuration area. That is OK for now.
Switch the processor to Run Mode with the dropdown menu (just to the left of where it
currently says “Rem Prog”).
Please note that if you were connected to a PLC that is operating a machine, you
would take much greater care when switching to Run Mode.
A ControlLogix PLC has a key switch with three positions: RUN (run mode), REM
(remote mode, meaning that the mode can be selected from RSLogix) and PROG
(program mode).
The three modes work this way:
Turning the key switch to RUN puts the processor in RUN mode. RSLogix can only
monitor the program and data. No downloads or changes to the program can be
mode.
129
REM allows RSLogix to put the PLC in Remote Run mode or Remote Program mode.
Most often, the key switch is left permanently in this position.
PROG lets RSLogix upload or download programs, change data, etc. However,
RSLogix cannot put the PLC in Run mode with the switch in this position.
Hide the Controller Organizer and your screen looks like this.
We could have chosen “Test Mode”. This is a special mode
that allows the program to run, but disables all outputs. This would be a
good practice if we were on an actual start-up and personnel and
equipment safety was an issue.
130
You can see that the “E-STOP Cleared PB3” bit is off, making the XIC instruction off as
indicated by the lack of a green highlight on the instruction.
It seems we have a system fault. We know that the “SystemFault” bit is on, since the
XIO instruction in Rung 0 is false. Again, a true state is indicated by the green highlight
on the instruction.
Remember:
The XIC (normally open) instruction tells the PLC to look at a bit, and if the bit is
ON, then the instruction is true.
The XIO (normally closed) instruction tells the PLC to look at a bit, and if the bit is
OFF, then the instruction is true.
Let’s find out why we have a system fault.
Right-click on the “SystemFault” tag name in Rung 0. Choose Find All “System Fault”
131
A new window appears at the bottom, showing links to all the occurrences of
“SystemFault”. Click on the link that contains the OTE.
We can see that the valve fault timers have timed out, turned on their respective done
bits (DN) and caused a system fault.
Scroll up a rung and you will see that the output for mixing tank valve AV-MT on
Local:4:O.Data.13 is not energized. In the lower branch of Rung 21 you can see that the
input Local:I.Data.8 from the mixing tank valve AV-MT closed limit switch is not
energized.
Normally, of course, if we were telling the valve to close, we would get a signal from the
limit switch on the input.
We are going to have to temporarily disable the system fault bit so that we can test the
remainder of the program. We will do this by putting a “jumper” across the
“SystemFault” instruction in Rung 0.
Close the search window at the bottom of the screen.
132
Scroll to Rung 0 and double-click to the left of the rung. Your screen looks like this.
The rung you are editing is a copy of Rung 0 and has the letter “i” to the left. The rung
shown below has the letter “r” to the left, indicating that the PLC is still running this rung.
133
Find the “Branch” icon in the toolbar.
134
Click and drag the branch to Rung 0.
Small squares on the rung indicate potential landing spots for the branch. As you near a
spot, the icon changes to a green circle. When the cursor is near the landing spot in
front of the “SystemFault” bit, release the mouse button.
135
Your screen looks like this.
136
Click and drag the right part of the branch and place it to the right of the “SystemFault”
instruction.
137
Find the “Finalize Edits” button in the toolbar.
138
Click it and you will see this dialog box.
This is warning you that, among other things, the change cannot be undone (without reediting the rung, at least – there is no “undo”.
Click the “Yes” button.
139
You see that the letters to the left of the rungs are gone. The PLC is now processing
Rung 0 with the new logic.
However, the “SystemEnable” bit is still off. That is because we are not getting a signal
from the “E-Stop Cleared PB3”.
RSLogix allows you to toggle the state of a bit. It will remain toggled unless logic, or
voltage on an input, forces it to another state.
Since there is no voltage on the “E-Stop Cleared PB3 Local:3:I.Data.15” input, we can
toggle it.
Right-click on the instruction.
Choose “Toggle Bit”.
140
Now, the E-stop input instruction is true, as indicated by the green highlight. Also, the
“SystemEnable” OTE is true. The “SystemEnable” XIO instruction in Rung 1 is also true.
Since the all the preceding instructions are true, the “SystemEnable” OTE is true.
The system is now enabled.
Take a moment to think of the equivalent hardwired relay circuit that would generate the
same function as Rung 0.
Imagine that we have a pushbutton switch, labeled E-STOP Cleared PB3, and two
relays, SystemFault and SystemEnable. We have wired a normally open contact of ESTOP Cleared PB3 in series to a normally closed contact of SystemFault and to the coil
of SystemEnable.
We are pushing the button on switch E-STOP Cleared PB3, so the normally open
contact is closed. The coil for relay SystemFault is energized, so the normally closed
contacts of SystemFault are open. However, we have placed a jumper across this set of
contacts. This energizes the coil of the SystemEnable relay.
141
Don’t forget to remove any temporary jumpers like this after you
are done testing.
Let’s start a batch by toggling the “Start Batch PB1” in Rung 1. You see that the
“SystemBatching” bit becomes true and the latch is now active. Toggle it again to the off
state to simulate how the pushbutton actually works.
In Rung 1, we can see that the system is batching as shown by the OTE instruction
used with “SystemBatching”.
142
Look at Rung 4. The first two instructions look right, as the system is batching and we
are in Batch Step 1. Both of these are highlighted.
The outputs are also true.
However, the LEQ (less than or equal to) is not highlighted; Source A is 0, which is
certainly less than the value of 1665 in Source B.
RSLogix does not highlight some instructions even though they are true, such as an
LEQ. You have to mentally compare the numbers yourself to see if the instruction is
true.
143
In Rung 3, the latch “Adding City Water BatchStep1” is turned on. Even though the start
pushbutton has been released, the latch instruction will stay on.
The latch instruction and will remain on until the corresponding unlatch instruction is
true.
144
Scroll to Rung 5. The liquid weight still shows 0.
We can simulate adding water to the tank.
145
Double-click on the value for Source A in the GEQ instruction in Rung 5. Change it to
1275.
Press enter.
146
The program has incremented to the next step.
You see that the “Adding City Water BatchStep1” output is turned off. The bit “Adding
Chemical QR BatchStep2” is turned on.
During your testing, you will continue this sequence until the specified weight for each
ingredient is reached.
As the ingredients are added, the tank weight rises. When all the ingredients have been
added, the batch is blended and sent to the filling lines.
In a real-world start-up scenario, you would verify each step of the process and confirm
that the program functions as specified in the original Project Scope.
147
Editing in Run Mode
As happens many times, though, there is a change in the project procedure.
There is a storage tank on the filling lines that Mixing Tank Pump PUMP-MT feeds. The
Process Engineer indicates that there may be a possibility of supplying too much
finished product to this tank and that it could overflow. He decides the storage tank
should have a high level switch mounted in it. If the level in the storage tank gets too
high, he wants you to disable the Mixing Tank pump.
We still have spare inputs available. Let’s use Local:3:O.Data.14. It is decided that the
high level switch will be wired in the failsafe mode; that is, the level switch will be closed
until a high level is reach. When wired in that fashion, if the wiring to the switch fails, you
will not receive a signal from the storage tank pump and the PLC will stop the Mixing
Tank Pump. The system will not run until the problem is corrected.
Scroll to Rung 16. Double-click on the rung number. A column of “i’s” will appear. The
rung is now open for editing.
Click and drag the XIC tool button to the first marker after Local:3:I.Data.9. When the
marker turns green, release the mouse button.
148
Press enter. You may also click on the tag field. Type the tag name
“FillingLineStorageTankReady” and press enter.
149
Right-click on the new tag and choose New FillingLineStorageTankReady.
150
A dialog for the new tag opens. In this case, we can accept the defaults and click the
“OK” button.
Click the “Finalize All Edits in Program”.
151
Your online edit is now complete. The Mixing Tank pump will not run unless it receives a
signal from the Filling Line Storage tank indicating the tank is ready to receive finished
product.
If you want to cancel your current edits, click the tool to the
immediate right of the “Accept Pending Program Edits” tool. This is called
“Cancel Pending Program Edits”.
152
Run Mode on the Plant Floor
After you have connected to your PLC and downloaded your program, you are ready to
begin your testing. However, before you go into Run Mode, make sure that the E-stop
circuit works properly. I have not included wiring diagrams in this book, but most
codes state that all control power is removed if the E-Stop button is pressed.
NFPA 79 Electrical Standard for Industrial Machinery states the following:
“9.2.2* Stop Functions. The three categories of stop functions
shall be as follows:
(1) Category 0 is an uncontrolled stop by immediately removing
power to the machine actuators . . .
9.2.5.4.1 Emergency Stop. Emergency stop functions provided
in accordance with 9.2.5.3 shall be designed to be initiated
by a single human action.
9.2.5.4.1.1 In addition to the requirements for stop, the
emergency stop shall have the following requirements:
(1) It shall override all other functions and operations in all
modes.
(2) Power to the machine actuators, which causes a hazardous
condition(s), shall be removed as quickly as possible
without creating other hazards . . .
(3) Reset of an emergency stop circuit shall not initiate a restart.”
(National Fire Protection Association, 79-22, 79-23)
Make sure you follow your company’s start-up procedures as you begin testing the
system.
Test your E-Stop circuit thoroughly, even if you are working on
a system that has been running for months or years. Be ready to hit the EStop button if you see a hazardous situation developing.
153
Add-On Instructions & Function Block
Diagram Programming
A function block routine consists of a series of sheets. You can navigate to any sheet in
the routine, and add and remove sheets as you wish. The function block editor displays
only one sheet at a time.
Function blocks are intended to provide a graphical programming interface, like those
used in many high-end DCS interfaces.
An Add-On Instruction (AOI) is a custom routine built with function blocks. You can write
your own “function” and use it as often as you like.
To show an example of a function block diagram, let’s use some ladder logic from our
program. We can see that this rung simply performs the Boolean AND function by
putting the necessary instructions in series with the output, as shown below.
AOIs
Before we go too much further, I need to tell you that there are differing opinions on the
use of function block diagrams and add-on instructions in RSLogix 5000. Most
programmers do not use them, as they are difficult to troubleshoot and only add value in
some situations.
154
In versions 16.03 and below of RSLogix, you cannot change the programming in an
add-on instruction while the system is in run mode. This, as you know, could be a major
problem. Until Rockwell addresses this, it will continue to be a deterrent to using AOIs.
If, though, you have a programming scenario where the exact same logic must be
repeated many times, it might make sense to create your own AOI.
Take as an example the way we monitored the valves in our program for faults. The
fault detection logic is the same for all four valves. We could have developed an AOI
that we could “plug in” to each valve.
One of the factors that determine whether ladder logic or an AOI should be used is the
number of occurrences of the repeating logic. In our program, we have only 4 valves. It
would not be worth the time to write and debug an AOI if we were going to use it only 4
times.
If we had 15 valves, then it would probably be worth the effort. That way, if we decided
to change the valve fault detection logic later, we need only change the ladder logic in
one place.
In summary, the advantages of AOIs are this:
-
AOIs use repeatable, tested code that simplifies programming.
-
AOIs make it easy to change the repeating code (if the PLC can be taken offline).
The disadvantages are:
-
The ladder logic that comprises an AOI cannot be edited online.
-
Function Block Diagrams can become very complex and difficult to follow and
troubleshoot in RSLogix 5000.
-
Revision history of an AOI may be difficult to track. You may revise an AOI for a
machine that is going to Client G that is different in function, but carries the same
name, as an AOI that went to Client B a few months ago.
Use your discretion. Having said that, let’s create the function block diagram that could
replace Rung 3.
155
Creating a Function Block Diagram
In the Controller Organizer, right-click on “Main Program” and choose “New Routine”.
Fill in the fields as shown below.
Click “OK”.
The “AddCityWater” routine is now shown as a Function Block diagram in the Controller
Organizer. Double-click on it. Right-click on the sheet.
156
Choose “Add Element”. Expand the “Move/Logical” section and choose “BAND Boolean
And”.
The BAND function appears.
157
Click the “…” button in the function. The configuration screen appears.
Since there are 6 “input” instructions in the rung we are trying replace, check the “Vis”
boxes for In5 and In6. Click “OK”.
Click the drag the whole function n=block to the right. Right-click on a blank part of the
sheet and choose “Add Element”. Select “Input Reference”. Click on the input block to
access the tag list. Choose “SystemBatching”, which is the first bit in Rung 3. Click and
drag a line from the right side “tip” of the input reference to In1 on the BAND.
158
The diagram now looks like this.
Add the remaining inputs. Before you connect the lines, notice that some of the inputs
need to be inverted to match the logic of Rung 3. Change the “Value” field in the
BAND’s configuration to be 0 when the input is on.
159
The function block diagram looks like this.
We have not addressed the output, or the fact that the output must be latched, but you
should now be familiar enough with function block programming to understand the
benefits and drawbacks.
160
A Final Note About Our Program
You may have noticed that we ignored some aspects of the system that perhaps should
have been addressed.
For example, in a real world system, you would probably have to make sure that the
supply of ingredients QR and KM are available. If not, the pumps could run dry, and this
is probably undesirable.
Another nice feature of the program would be to make sure the weight in the tank is
changing if we are adding an ingredient. If not, this certainly indicates some kind of
problem and the system should probably be shut down.
I have intentionally left out features like this for simplicity’s sake. I don’t want to
overwhelm you with too many “what ifs”.
The bottom line is that we fulfilled the Project Scope. This is the single most important
aspect of creating a successful program.
Feel free to ponder enhancements to this batching logic. Perhaps you can use those
ideas on your first real-world batching program.
161
How Do I . . . ?
Here is an FAQ section to address the most asked questions regarding RSLogix.
How do I . . . ?
Turn off Rung Comments
Tools > Options > Ladder Editor > Display uncheck Show Rung Comments
Change The Screen Font
Tools > Options > Ladder Editor > Fonts
Find An Instruction In The Program When You Only Know Some Of The
Descriptor Or Rung Comment
Press CTRL-F. Make sure the appropriate right boxes are checked. Type the text in the
“Find What:” box. Click “Find Next” or “Find All”.
Open Another Program, But Still Keep My Existing Program On Screen
Just start RSLogix again. You can open a number of RSLogix windows simultaneously.
Force An Output On A Module To Come On
Right-click on the output in the ladder logic. Choose “Force On”.
In the Forces Disabled/Enabled drop down, choose “I/O Forces > Enable All Forces”.
This will force on the output and turn on the device that is connected to the
output, no matter what the logic in the rung says. The corresponding LED on the
output module will come on. Use this with caution.
162
Force An Input On A Module To Come On
This differs from forcing on an output in that you can’t force electricity to become
present at an input, but the PLC will think there is.
Right-click on the input in the ladder logic. Choose “Force On”. Unlike forcing an output,
the corresponding LED in the input module will not come on.
Get Help On A Specific Instruction
Choose Help > Instruction Help
Disconnect From The PLC After All The Programming Changes Are Made
Choose File > Save (save the data tables). Disconnect the interface cable.
163
Tips, Shortcuts and Warnings
RSLogix 5000 Allows The Use Of “Serial” Logic That Does Not Conform To
Traditional, Electrical Ladder Logic.
For example, both of the rungs shown below are valid in RSLogix 5000.
Clearly, the second version would not work if wired that way in an equivalent electrical
circuit. It would not be allowed in RSLogix 500, either.
The main advantage, in my opinion, to writing the code as it is shown in the second
version is that you can get more instructions on the screen, and that involves less
scrolling. And, the logic is slightly different; if something turns off the “SystemReady” bit
somewhere lese in the program, PL1 would not come on.
The main disadvantage, in my experience, is that the second version will drive
electricians and maintenance people crazy, if they are not familiar with RSLogix 5000.
Their managers will most likely request that you re-write the rung in “traditional” ladder
logic.
164
The Date Attribute Of The File Is Updated Every Time You Go Online Even If You
Don’t Save The Program.
Keep this in mind as you track your revisions.
Use Search And Replace With Caution.
Try to avoid the “Replace All” button unless you are absolutely, positively sure that
things will come out right. There is no “Undo”.
It is much safer to use the “Find Next” and “Replace” buttons. That way you can
evaluate each change you make.
Don’t Fault The Processor In Run Mode.
Make sure you don’t ask the PLC to do anything like dividing by zero. The PLC will fault
and the machine will stop. This can be very embarrassing.
Backup Your Files Frequently.
The easiest way is to “rev” your filename every so often, at least once every 30 minutes.
Choose File > Save as and put a number in the filename.
Sometimes, files are corrupted through no fault of your own. You can always go back to
the previous version so that you have not lost all of your work.
Disable A Rung With An AFI.
If you want to temporarily disable a rung, use the AFI instruction in the first position of
the rung.
Don’t Turn Off Power To The PLC OR Your Computer During An Online Edit.
There is a good chance this will corrupt your current file.
165
Keep The Original Program In A Very Safe Place.
If you need to make some changes on an existing program, upload the program from
the PLC and store it on a floppy or a CD. If things go awry with your editing, you can
always put the program back the way it was.
Keep Track Of What You Are Doing If You Modify An Existing Program.
People will want to know.
Rung Comments Are Extremely Important.
Not only will they explain the operation of the program to someone else, they will remind
you of why you programmed the logic the way you did.
Use Passwords Carefully.
If you use one, don’t forget it . . . but if you do, your Rockwell rep can show you how to
get around it.
Make Sure Your Program Is Programmed Properly For A System Power-Up.
There must be no machine motion until the operator initiates it.
Set Up A Printout.
Choose File > Print Options. This shows you everything you can print. If you are not careful,
though, you may get hundreds of pages, many of which you don’t need. Use the “Print
Preview” button to make sure you are getting only what you want.
Use CTRL-G To Goto Places Real Fast.
In the ladder editor, CTRL-G brings up a dialog box. Enter in a rung number or text to
go to the first occurrence of the search string.
166
When You Are Done, Store Your Program To The EEPROM In The PLC.
It is a good idea to save your ladder file to the EEPROM. The onboard battery will keep
your program in the PLC’s RAM, but if the battery fails, the EEPROM will hold the
program.
Use The Built-In Automatic Program Backup
Choose Tools > Options… and set your Project Files Search Path. Make sure AutoSave is
enabled. RSLogix will automatically save your file every few minutes (the default is 10
minutes).
Write Your Rung Comments In The Present Tense.
You can then cut and paste them into a document to make an operator’s manual.
Write Your Rung Comments In A Standalone Word Processor (such as Word)
Spell check them, then cut and paste them into RSLogix.
Conclusion
I hope that you have found the information in this book useful. Some of the concepts we
have covered may seem confusing at first, but with time and effort, you will be able to
program a PLC to do whatever you want it to do.
I wish you the best of luck in your endeavors.
167
THE FOLLOWING ARE TRADEMARKS OF ROCKWELL AUTOMATION, INC.
Allen-Bradley®
ControlLogix™
CompactLogix™
MicroLogix™
PanelView™
RSLinx®
RSLogix™
RSLogix™ 5000
RSView32®
SLC™ 500
THE AUTHOR OR THE PUBLISHER OF THIS BOOK IS IN NO WAY AFFILIATED WITH ROCKWELL AUTOMATION, INC.
Disclaimer
THE AUTHOR INTENDS THIS DOCUMENT TO BE ADVISORY ONLY. ITS USE IN INDUSTRY OR TRADE IS
STRICTLY VOLUNTARY.
THIS DOCUMENT IS PROVIDED BY THE VENDOR “AS IS'' AND ANY EXPRESSED OR IMPLIED WARRANTIES,
INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE ARE DISCLAIMED. IN NO EVENT SHALL THE VENDOR OR ITS CONTRIBUTORS BE
LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL, SPECIAL, EXEMPLARY, OR CONSEQUENTIAL DAMAGES
(INCLUDING, BUT NOT LIMITED TO, PROCUREMENT OF SUBSTITUTE GOODS OR SERVICES; LOSS OF USE,
DATA, OR PROFITS; OR BUSINESS INTERRUPTION) HOWEVER CAUSED AND ON ANY THEORY OF
LIABILITY, WHETHER IN CONTRACT, STRICT LIABILITY, OR TORT (INCLUDING NEGLIGENCE OR
OTHERWISE) ARISING IN ANY WAY OUT OF THE USE OF THIS DOCUMENT, EVEN IF ADVISED OF THE
POSSIBILITY OF SUCH DAMAGE.
Courtesy of Rockwell Automation, Inc.
168

2003 Softail FXSTD / FXSTDI Softail Deuce

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